US10710197B2 - Method and system for the remote laser welding of two coated sheets - Google Patents

Method and system for the remote laser welding of two coated sheets Download PDF

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Publication number
US10710197B2
US10710197B2 US14/565,670 US201414565670A US10710197B2 US 10710197 B2 US10710197 B2 US 10710197B2 US 201414565670 A US201414565670 A US 201414565670A US 10710197 B2 US10710197 B2 US 10710197B2
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Prior art keywords
sheets
weld
laser beam
scanner
fillet weld
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US14/565,670
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US20150144606A1 (en
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Christian Roos
Florian Oefele
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/242—Fillet welding, i.e. involving a weld of substantially triangular cross section joining two parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • B23K26/032—Observing, e.g. monitoring, the workpiece using optical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/04—Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
    • B23K26/044—Seam tracking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/60—Preliminary treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/34—Coated articles ; Surface treated articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys

Definitions

  • the invention relates to a method for the laser remote welding of at least two coated sheets, wherein the laser beam is directed onto the sheets to be joined to one another and guided thereon by way of a scanner device. Further, the invention also relates to a system for carrying out the method.
  • a method of the kind mentioned in the introduction is disclosed in DE 103 09 157 B4.
  • the coated sheets to be joined are positioned on top of one another, as far as possible without a gap.
  • the sheet facing the laser beam is first heated by the laser beam, wherein the coating of both sheets vaporizes on their mutually facing sides and is distributed between the sheets without the basic material of the sheets melting.
  • the two sheets are welded by the laser beam in the region where the coating has been removed and in this way joined to one another by material-to-material bonding.
  • the invention is based on the object of providing a method of the above-mentioned type that does not have, or at least minimizes, the disadvantages which accompany the prior art.
  • the coated sheets are joined to one another by producing an end fillet weld on a lap joint, wherein the continuous production of the weld is recorded by (at least one) imaging unit and, if necessary, the path of the laser beam (on the sheets to be joined) is corrected and matched to a desired weld course on the basis of an automatic evaluation of recorded images (or a recorded video sequence or similar). In particular, this takes place during the ongoing welding process.
  • laser remote welding is understood to mean a welding process using scanner technology or a scanner.
  • the laser beam is deflected by at least one movable rotating mirror or scanner mirror, and is positioned and guided onto the sheets to be joined, whereby very high processing speeds can be realized.
  • the scanner can also have lens systems for focusing the laser beam.
  • the welding operation is typically carried out without filler metals.
  • An “end fillet weld on a lap joint” is particularly understood to mean a welded joint between at least two sheets, wherein a top sheet rests on a bottom sheet in an at least partially overlapping manner and the weld is formed between at least one edge surface or side surface of the top sheet and the adjacent contact surface of the bottom sheet.
  • Such a weld can also be referred to as a “side fillet weld”.
  • the end fillet weld can be formed as a continuous weld or in the manner of a stitch weld (i.e. with discontinuities in the weld).
  • the sheets to be joined to one another can be flat sheets (plates) or spatially formed sheets (shaped sheet metal parts).
  • the sheets are zinc-coated steel sheets.
  • the sheets can also be aluminum-coated steel sheets.
  • a zinc coating or aluminum coating is particularly understood to mean a zinc or aluminum-based anti-corrosion coating.
  • a further advantage of the method according to the invention is to be seen in that the two coated sheets to be joined are welded without a gap or without spacing (i.e. with so-called zero gap) by means of the at least one fillet weld.
  • a gap between the welded sheets is undesirable, as dirt and/or other corrosive media (in particular moisture) can penetrate, this being promoted by a capillary effect.
  • the coating vapor condenses between the sheets, which necessarily leads to a spacing between these sheets.
  • JP 11047967 A a spacing between the sheets (by means of melt craters) is provided from the outset, wherein the introduction of the melt craters for adjusting the gap constitutes a separate and elaborate operation.
  • the images or video sequences produced by the at least one imaging unit, such as a camera, and subsequently evaluated by way of a control unit are, in particular, grayscale image recordings.
  • the region recorded by the camera is additionally illuminated by at least one artificial light source, which, for example, is of advantage with regard to smoke and vapor or a larger camera distance.
  • the artificial light source can be built into the scanner, for example, or fixed externally on the scanner.
  • the camera can also be built into the scanner or fixed externally on the scanner.
  • the recorded images can be evaluated with regard to the weld course with reference to the step offset between the sheets, which is necessarily present on account of the overlap.
  • the position of the generated fillet weld can be easily identified on the recorded images and correlated with the step offset. This then allows a determination of the actual position of the laser beam and the calculation of a corrective movement, which is then realized by appropriate conversion by use of the scanner or the scanner mirror incorporated therein.
  • a first method step it can be provided that initially only the coatings (of the sheets) are vaporized with the laser beam (i.e. removed by vaporization) in the region of the end fillet weld to be applied, and that then, in a second method step, the sheets are welded with the same laser beam in the areas with the coating removed.
  • the different energy contribution required in the individual method steps can, for example, be adjusted by the traversing speed of the laser beam (and/or, if necessary, also the number of traversals).
  • the laser beam is actually widened by defocusing or oscillation, so that the coating can be vaporized in a relatively wide strip (without the sheet base material otherwise melting).
  • the coatings (of the sheets) are vaporized with a separate (second) laser beam in the region of the end fillet weld to be applied, wherein this separate laser beam leads the (first) laser beam for the welding operation. Accordingly, two laser beams are required here, but only one operation. Two laser beams can be implemented, for example, by two scanner devices or by so-called double-focus technology.
  • the images or video sequences recorded by the camera can also be automatically evaluated with regard to checking the quality of the generated end fillet weld, for example with regard to spatter, pores, cracks and the like.
  • the automated evaluation can be undertaken by the control unit. This enables the quality of the generated end fillet weld to be checked by automated inspection without significant increase in effort or cost.
  • Various possibilities for visual inspection of the weld quality are known from the prior art.
  • the desired weld course is determined or defined, which, among other things, can include a shortening and smoothing of the weld course, an optimization of the speed, an accessibility and collision check, a cycle time optimization and/or a sequence planning of a plurality of end fillet welds.
  • this is CAD-based. This can also be referred to as off-line path planning.
  • the system according to the invention for the laser remote welding of two coated sheets comprises:
  • the scanner is mounted on a movable mechanism.
  • a movable mechanism is, for example, a robot, a gantry or the like.
  • the working area can be increased by moving the scanner to different positions by way of the movable mechanism. If the traverse movements of the scanner take place simultaneously with the welding operation, this is referred to as welding “on the fly”, as a result of which processing times can be considerably shortened. On the fly welding requires a synchronization of the movements (i.e. movement of the laser beam by the scanner and movement of the scanner by the mechanism), which can be taken into account both with the off-line path planning and with the online weld tracking.
  • the control device is then designed or constructed appropriately for this purpose.
  • FIG. 1 shows two sheets joined to one another by way of an end fillet weld in a plan view
  • FIG. 2 shows a section through the end fillet weld from FIG. 1 ;
  • FIG. 3 shows a system according to an embodiment of the invention for laser remote welding in a schematic view.
  • FIG. 1 shows two coated flat sheets 10 and 20 , which are arranged overlapping one another or with a lap joint and are joined to one another by material-to-material bonding by way of a straight end fillet weld 30 .
  • the sheet 10 can be designated as the bottom sheet and the sheet 20 as the top sheet.
  • the top sheet 20 can rest completely on the bottom sheet 10 and be joined to the bottom sheet 10 by way of peripheral end or side fillet welds.
  • An end fillet weld 30 can also have a course which is curved in one plane and, if necessary, also curved spatially.
  • FIG. 2 shows a section through the end fillet weld 30 .
  • the form of the weld which is formed between the edge surface or side surface of the top sheet 20 and the adjacent contact surface of the bottom sheet 10 , can be clearly seen in this diagram.
  • the top sheet 20 is positioned and aligned on the bottom sheet 10 .
  • the coated sheets 10 and 20 are then welded with a laser beam, which can be carried out on the system explained below in conjunction with FIG. 3 .
  • FIG. 3 shows a system for laser remote welding which is designated as a whole by 100 .
  • the system 100 includes a scanner 110 , which is known as such from the prior art and is fixed to a robot arm 120 of a robot by way of a flange 125 .
  • the scanner 110 can be moved in space by the robot, which is illustrated by the double arrows. This enables welding “on the fly” to be carried out as explained above.
  • the system 100 includes an illumination device 130 which is fixed to the scanner 110 , and an imaging device 140 , such as a camera which is likewise fixed to the scanner 110 .
  • the system 100 also includes a control unit 150 which is connected by way of interfaces (not shown) to the scanner 110 , the illumination device 130 , the camera 140 and the robot.
  • a laser beam L is then directed by way of the scanner 110 onto the sheets 10 and 20 , which are arranged below the scanner 110 , and guided along a specified path (desired weld course) over the sheets 10 and 20 (see arrow in FIG. 3 ), wherein an end fillet weld 30 as described above is formed.
  • the formation of an end fillet weld 30 leads to good degassing conditions for the coating material, which vaporizes due to the heat introduced by the laser beam (as explained in detail above). Further possible ways of removing the coating from the sheets 10 and 20 are described above. Further, the end fillet weld allows the sheets 10 and 20 to be joined without a gap (as likewise explained in detail above).
  • the distance between the scanner 110 and the sheets 10 / 20 is, for example, 0.5 m or more, which increasingly leads to position errors.
  • the end fillet weld 30 produced is continuously recorded by the camera 140 , wherein the recorded region (this is typically the process zone directly and the zone immediately following the process zone) can be additionally illuminated by the illumination device 130 .
  • the actual weld course is automatically evaluated by the control unit 150 , for example by comparison with the step offset between the sheets 10 and 20 .
  • the path of the laser beam L is corrected and matched to the desired weld course, which is likewise initiated by the control unit 150 , which actuates the scanner 110 and/or the robot appropriately for this purpose.
  • the path can be matched with an accuracy of +/ ⁇ 100 ⁇ m.
  • a quality control or quality check of the generated end fillet weld 30 can be undertaken on the basis of the images recorded by the camera 140 as already explained.
  • these can also be coupled within the scanner 110 , which can take place with the help of mirrors, for example.

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Laser Beam Processing (AREA)
US14/565,670 2012-06-14 2014-12-10 Method and system for the remote laser welding of two coated sheets Active 2034-04-02 US10710197B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE102012210012A DE102012210012A1 (de) 2012-06-14 2012-06-14 Verfahren und Vorrichtung zum Laser-Remote-Schweißen von zwei beschichteten Blechen
DE102012210012 2012-06-14
DE102012210012.1 2012-06-14
PCT/EP2013/062158 WO2013186262A1 (de) 2012-06-14 2013-06-12 Verfahren und vorrichtung zum laser-remote-schweissen von zwei beschichteten blechen

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2013/062158 Continuation WO2013186262A1 (de) 2012-06-14 2013-06-12 Verfahren und vorrichtung zum laser-remote-schweissen von zwei beschichteten blechen

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US20150144606A1 US20150144606A1 (en) 2015-05-28
US10710197B2 true US10710197B2 (en) 2020-07-14

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US (1) US10710197B2 (de)
EP (1) EP2861371B1 (de)
CN (1) CN104169039B (de)
DE (1) DE102012210012A1 (de)
WO (1) WO2013186262A1 (de)

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DE102014205142A1 (de) * 2014-03-19 2015-09-24 Mahle International Gmbh Verfahren zum Erzeugen eines Bildes eines abzubildenden Objekts mittels einer eine verstellbare Scanner-Optik umfassende Scanner-Anordnung
DE102015106339B4 (de) * 2015-04-24 2017-02-23 Kirchhoff Automotive Deutschland Gmbh Verfahren zum stirnseitigen Laserschweißen der Stöße von zwei aneinandergrenzend gehaltenen Fügeflanschen
CN106514063A (zh) * 2015-09-15 2017-03-22 苏州中启维盛机器人科技有限公司 薄板焊接机器人
DE102015223446A1 (de) 2015-11-26 2017-06-01 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Remote-Laserstrahlschweißen
US20180021888A1 (en) * 2016-07-22 2018-01-25 Illinois Tool Works Inc. Laser welding systems for aluminum alloys and methods of laser welding aluminum alloys
CN106583925B (zh) * 2016-12-07 2018-07-31 上海临仕激光科技有限公司 一种汽车用镀锌钢板的激光焊接方法
DE102017209599B4 (de) * 2017-06-07 2026-05-07 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung eines Bauteilverbundes und Bauteilverbund
CN107414318A (zh) * 2017-09-06 2017-12-01 青岛科捷机器人有限公司 一种用于激光切割头定位的固定式扫描定位装置及方法
CN107363424A (zh) * 2017-09-06 2017-11-21 青岛科捷机器人有限公司 一种用于激光切割头定位的随动式扫描定位装置及方法
DE102017128763B4 (de) * 2017-12-04 2022-01-05 Precitec Gmbh & Co. Kg Laserstrahl-Schweißverfahren zum Verschweißen von wenigstens zwei Werkstücken
DE102019212403B4 (de) * 2019-08-20 2022-04-07 Trumpf Laser- Und Systemtechnik Gmbh Verfahren zur Regelung mindestens eines Bearbeitungsparameters anhand mindestens eines Spritzermerkmals sowie zugehörige Bearbeitungsmaschine und Computerprogrammprodukt
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DE102022118911A1 (de) * 2022-07-28 2024-02-08 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Dokumentation zumindest einer Fügeverbindung an einer Fügestelle sowie Datenverarbeitungsvorrichtung
DE102024002504B4 (de) 2024-08-01 2026-02-05 Mercedes-Benz Group AG Verfahren zur Regelung eines Fügeprozesses

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DE102012210012A1 (de) 2013-12-19
CN104169039A (zh) 2014-11-26
WO2013186262A1 (de) 2013-12-19
EP2861371B1 (de) 2019-08-14
US20150144606A1 (en) 2015-05-28
CN104169039B (zh) 2016-08-24
EP2861371A1 (de) 2015-04-22

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